Soloset secondary igniter

ABSTRACT

A system for a self-ignitable secondary igniter. The system includes an outer wall extending for a length. The outer wall has a first end and a second end, and the outer wall is filled with a charge. The first end has a centralized-contact spring which is in contact with the outer wall. The centralized-contact spring has a recess and at least one leaf which contacts the outer wall. The system can further include an igniter coupled to the recess of the centralized-contact spring.

PRIORITY

The present invention claims priority to U.S. Provisional Application No. 63/055,141 filed Jul. 22, 2020, the entirety of both of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION Technical Field

The present invention relates to a system and method for a power charge.

Description of Related Art

Power charges are inserted downhole for a variety of purposes. The power charges are inserted downhole via wireline or other device and are used to provide a force downhole. Often the power charges require a primary igniter to function. Consequently, there is a need for an improved power charge.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:

FIG. 1 is a side view of a power charge in one embodiment;

FIG. 2 is a side view of a power charge prior to the self-ignitable secondary igniter being installed in one embodiment;

FIG. 3A is a perspective view of various self-ignitable secondary igniters in one embodiment.

FIG. 3B is a perspective view of various self-ignitable secondary igniters in one embodiment.

FIG. 3C is a perspective view of various self-ignitable secondary igniters in one embodiment.

DETAILED DESCRIPTION

Several embodiments of Applicant's invention will now be described with reference to the drawings. Unless otherwise noted, like elements will be identified by identical numbers throughout all figures. The invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.

Power charges have widespread use in the oil and gas industry. They can be used in setting tools such as plugs, packers, etc. When burned the power charge creates pressure greater than 10,000 psi. The pressure causes a tool to stroke, setting it in the desired place or performing any such desired task.

FIG. 1 is a side view of a power charge in one embodiment. As seen the power charge 100 is cylindrical. This is for illustrative purposes only and should not be deemed limiting. The power charge 100 can comprise a cross-section of virtually any shape including circular, oval, triangular, square, tubular with a hole through the center etc. In the embodiment depicted the power charge 100 is cylindrical so it can be placed downhole.

The power charge 100 has an outer wall 102. The outer wall 102 serves several functions. First, the outer wall 102 acts to secure the contents of the power charge 100, as discussed in more detail below. The power charge 100 can be handled, moved, etc. without spilling the contents because of the outer wall 102. Second, the outer wall 102 provides a structure, and specifically a void which can be filled with a self-ignitable secondary igniter.

The outer wall 102 can comprise virtually any combustible material. The outer wall 102 can comprise paper, plastic, cardboard, etc. Virtually any material which can burn can be utilized as the outer wall 102. While one embodiment utilizes a separate outer wall 102, in some embodiments the outer wall 102 is the same material as the power charge 100. Thus, the outer wall 102 and the power charge 100 comprise the same material.

In one embodiment the outer wall 102 extends longitudinally along the entire length of the power charge 100. In this fashion, the outer wall acts to contain the internal contents.

As depicted the power charge 100 comprises a first end 111 and an opposing second end 112. In one embodiment the combustible contents of the power charge 100 extends continuously from the first end 111 to the opposing second end 112. In one embodiment the power charge 100 is filled so as to ensure there are no bubbles, gaps, or voids, within the outer wall 102.

The power charge 100 can comprise virtually any combustible substance. The ratio and contents of the ingredients can be adjusted depending upon the application. The ingredients can include potassium nitrate, sodium nitrate, strontium nitrate; ammonium nitrate, hydroxylammonium nitrate, ammonium perchlorate; Pydrodex, wheat flour, white flour, various other flours, and other ingredients. The ingredients can form a consistency similar to dough. The ingredients can further include a binder or epoxy to help the dough harden or cure. In one embodiment the power charge 100 comprises two parts epoxies and plasticizer to give the power charge 100 the characteristics of a bare or naked power charge.

As shown, coupled to the power charge 100 is a centralized-contact spring 103. The shape of the centralized-contact spring 103, in one embodiment, is more easily seen in FIG. 2. FIG. 2 is a side view of a power charge prior to the igniter being installed in one embodiment.

The centralized-contact spring 103 serves to mate with the outer wall 102 and to ground the self-ignitable secondary igniter 105. In one embodiment the centralized-contact spring 103 is cast onto the power charge 100 at one or both ends. Because in some embodiments, it is manufactured with the power charge 100, it is intimately coupled with the power charge 100 and serves as a ground for the self-ignitable secondary igniter 105.

As depicted, the centralized-contact spring 103 has four separate contact leaves 108 which surround and contact the periphery of the power charge 100. The contact leaves 108 can have various lengths depending upon the application. As shown they comprise a curve which provides the spring force to ensure the leaves 108 maintain proper contact with the power charge 100 sufficiently to ground the self-ignitable secondary igniter 105.

Part of the centralized-contact spring 103 is a head 110 from which the one or more contact leaves 108 extend. In one embodiment the head 110 coincides with an end of the power charge 100.

As shown, the centralized-contact spring 103 further comprises a recess 109. The recess 109 is sized to receive a self-ignitable secondary igniter 105. FIG. 1 shows the self-ignitable secondary igniter 105 being received in the recess 109. As can be seen in FIG. 1, the self-ignitable secondary igniter 105 is grounded by contact with the centralized-contact spring 103 and the power charge 100.

In one embodiment, the power charge 100 is manufactured as shown in FIG. 2. As shown, the power charge 100 has a centralized-contact spring 103 but does not comprise a self-ignitable secondary igniter. Before being used, the power charge 100 is coupled with a self-ignitable secondary igniter, such as shown in FIG. 1.

While a centralized-contact spring 103 has been described, this is for illustrative purposes only and should not be deemed limiting. In some embodiments the spring 103 comprises any grounding mechanism which grounds the self-ignitable secondary igniter 105 with the power charge. As noted, while an external spring has been described, the device can comprise any mechanism which grounds the self-ignitable secondary igniter 105 with the power chare.

Turning back to FIG. 1, FIG. 1 shows the self-ignitable secondary igniter 105 being installed and coupled to the power charge 100. As shown, the first end 111 of the power charge 100 comprises a self-ignitable secondary igniter 105. Self-ignitable secondary igniter 105 is a material which can be readily ignited by an electrical charge and which will cause the power charge 101 to combust. Various materials known in the art can be used in the self-ignitable secondary igniter 105. In one embodiment the primary igniter 101 is primarily Pyrodex, but other black powder and black powder substitutes can be utilized. In other embodiments the self-ignitable secondary igniter 105 comprises Potassium Nitrate, gun powder, Triple 7, Pyrodex RS, Pyrodex P, Boron Powder, Aluminum Powder, Ferric Oxides and other ingredients. In one embodiment the self-ignitable secondary igniter 105 has two parts epoxies and plasticizers. The self-ignitable, or a soloset, can be initiated without the aid of an igniter.

As can be seen, the self-ignitable secondary igniter 105 on the first end 111 comprises an exposed outer face. As noted, this means the self-ignitable secondary igniter 101 has an external face which is accessible, and visible, on the first end. This allows for the ignition of the secondary igniter 105. The self-ignitable secondary igniter 105 then extends downstream into power charge 100 within the outer wall. As used herein, upstream and downstream refer to relative locations along the power charge. An item closer to the first end will be referred to as the upstream end whereas an object further away from the first end will be referred to as downstream. Thus, the second end 112 is downstream of the first end 111. As can be seen, the self-ignitable secondary igniter 105 extends downstream into the power charge.

The length of the self-ignitable secondary igniter 105 can vary depending upon the application. As depicted, the length of the self-ignitable secondary igniter is less than about 10% of the total length of the power charge 100. As noted, this is for illustrative purposes only and should not be deemed limiting.

FIG. 3 is a perspective view of various self-ignitable secondary igniters in one embodiment. In one embodiment at least an external face of each secondary igniter 105 is exposed and is accessible externally. This allows an electrical charge to be applied to the self-ignitable secondary igniter 105 to ignite the power charge 100. The electrical lines can be coupled to the power charge 100 via any method or device known in the art.

FIG. 3 shows three various embodiments. FIG. 3A shows an embodiment with a spring-loaded contact 106. FIG. 3B shows a button end contact 113. FIG. 3C shows a wire contact 107. While these three embodiments are depicted, this is for illustrative purposes only and should not be deemed limiting. Those skilled in the art would understand other techniques and tools which allow an electrical current to be introduced and directed to a resistor 104.

In each of these embodiments the self-ignitable secondary igniter 105 comprises an internal resistor 104 or resistors connected in parallel or series. When sufficient current, voltage, etc. is applied to the resistor, it produces sufficient heat to ignite the self-ignitable secondary igniter 105. The ignition of the self-ignitable secondary igniter 105 causes the power charge 100 to ignite.

The self-ignitable secondary igniter 105 and power charge 100 disclosed herein has several benefits. First, in one embodiment the centralized-contact spring 103 can be made and cast simultaneously with the power charge 100. This ensures the centralized-contact spring 103 has an intimate coupling relationship with the power charge 100. As noted, the centralized-contact spring 103, and its contact with the power charge 100, creates an electrical ground. Additionally, in one embodiment, and as depicted, the centralized-contact spring 103 also serves the dual purpose of being a built-in housing/recess 109 for the subsequently added self-ignitable secondary igniter 105. This is a benefit in that the secondary igniter 105 need not be added until it is ready for use. By storing and transporting the power charge 100 separately from the secondary igniter 105, the possibility of an accidental ignition is greatly reduced.

Additionally, in embodiments wherein the centralized contact-spring 103 has a built-in recess 109, it is abundantly clear where the self-ignitable secondary igniter 105 is installed with the power charge 100. Incorrect installation or coupling of the self-ignitable secondary igniter 105 with the power charge 100 is decreased. Further, because the recess 109 is electrically coupled/grounded with the spring, so too is the self-ignitable secondary igniter 105 in contact with the recess 109.

In one embodiment the secondary igniter 105 is self-ignitable. This is a benefit because the secondary igniter 105 can be ignited directly rather than having to go through a primary igniter. This results in increased flexibility, versatility, and decreased cost.

In one embodiment the secondary igniter 105 is casted in a metal cup providing the bottom of it to be opened to allow the flame to travel once it is set. The metal cup allows the bottom end of the resistor to be electrically coupled, such as via soldering or the like, onto the cup. Then, the self-ignitable secondary is inserted in the centralizer spring making contact to the wall of the chamber creating ground for firing.

While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. 

What is claimed is:
 1. A system for a power charge, said system comprising: an outer wall extending for a length, wherein said outer wall comprises a first end and a second end; wherein said outer wall is filled with a charge; wherein said first end comprises a centralized-contact spring; wherein said centralized-contact spring is in contact with said outer wall; and wherein said centralized-contact spring comprises a recess; and wherein said centralized-contact spring comprises at least one contact leaf.
 2. The system of claim 1 further comprising an self-ignitable secondary igniter coupled with said recess.
 3. The system of claim 1 wherein said igniter comprises a resistor or several resistors.
 4. The system of claim 1 wherein said igniter is self-ignitable.
 5. The system of claim 2 wherein the secondary igniter is casted in a metal cup.
 6. The system of claim 5 wherein said cup has a bottom, wherein the bottom of said cup allows a flame to travel once set.
 7. The system of claim 6 further comprising a resistor, and wherein said resistor is electrically coupled to said cup.
 8. The system of claim 7 wherein the secondary igniter is inserted into said centralized spring.
 9. The system of claim 8 wherein contact between the centralized spring to the wall of the chamber creates ground for firing. 